Built-up deep deck unit for a roof or floor

Abstract

A deck unit is disclosed to form a deck system for a roof or floor that is capable of supporting a heavier load and/or spanning greater distances. The deck unit is a profiled, metal unit, that derives its greater load-bearing strength in part from its greater depth but provides flexibility in achieving the greater strength from the way the additional depth is obtained. In particular, a full length channel is attached to a hat-shaped profile. The channel adds strength both by increasing deck unit depth and by avoiding lengthening the webs on the hat-shaped profile. The channel increases design flexibility by allowing the designer to increase the strength of pre-existing decks by the addition of a channel of suitable metal thickness and size. It also provides a channel for conduit, cabling and wiring. The deck unit may be fluted or, by the addition of a liner panel to close the interior of hat-shaped profile, cellular. Sound absorbing materials can be installed in either a fluted or cellular deck unit.

What is claimed is: 
     
       1. A deck unit for use in constructing a roof or floor of a building, said deck unit comprising:
 a hat-shaped profile having a top flange and two opposing webs, each web of said two opposing webs having a bottom flange, said hat-shaped profile being made of sheet metal formed to have said hat-shaped profile; and 
 a box-like channel having at least two corners, a top between said two corners, and two opposing sides, said box-like channel contacting a top portion of said hat-shaped profile and supported by said webs of said hat-shaped profile to define a deck unit, said box-like channel being made of sheet metal formed to have a box-like profile, said box-like channel being supported by said hat-shaped profile to add depth to said hat-shaped profile, and wherein said bottom flange of said each web of said hat-shaped profile is joinable to a bottom flange of a web of an adjacent hat-shaped profile so that plural deck units are connectable to form a deck system for a roof or a floor. 
 
     
     
       2. The deck unit as recited in  claim 1 , wherein said deck unit further comprises a liner panel attached to said hat-shaped profile to define a cellular deck unit. 
     
     
       3. The deck unit as recited in  claim 2 , wherein said liner panel is perforated. 
     
     
       4. The deck unit as recited in  claim 2 , wherein said hat-shaped profile carries sound-absorbing materials. 
     
     
       5. The deck unit as recited in  claim 1 , wherein said webs are perforated. 
     
     
       6. The deck unit as recited in  claim 1 , wherein said top flange is perforated. 
     
     
       7. The deck unit as recited in  claim 1 , wherein said webs and said top flange are perforated. 
     
     
       8. The deck unit as recited in  claim 1 , further comprising stiffeners carried by said webs. 
     
     
       9. The deck unit as recited in  claim 1 , further comprising stiffeners carried by said top flange. 
     
     
       10. The deck unit as recited in  claim 1 , wherein said box-like channel has inwardly terminating terminal portions, and wherein said terminal portions are fastened to said top flange. 
     
     
       11. The deck unit as recited in  claim 1 , wherein said box-like channel has opposing terminal portions, and wherein said terminal portions are fastened to said opposing webs. 
     
     
       12. The deck unit as recited in  claim 1 , wherein said box-like channel is made of a first gauge of steel and said hat-shaped profile is made of a second gauge of steel, said first gauge of steel being a different gauge of steel than said second gauge of steel. 
     
     
       13. The deck unit as recited in  claim 1 , wherein said box-like channel has a cross-sectional area and a first end and an opposing second end, and said cross-sectional area varies from said first end to said second end. 
     
     
       14. The deck unit as recited in  claim 1 , further comprising sound-absorbing material carried within said box-like channel. 
     
     
       15. The deck unit as recited in  claim 1 , further comprising sound-absorbing material carried adjacent to and outside said hat-shaped profile. 
     
     
       16. The deck unit as recited in  claim 1 , further comprising sound-absorbing material carried within said box-like channel and adjacent to and outside said hat-shaped profile.